Cyclone assembly for surface cleaning apparatus and a surface cleaning apparatus having same

ABSTRACT

A cyclone assembly for a surface cleaning apparatus has a first cyclonic cleaning stage having a first end moveable between a closed position in which a first stage cyclone chamber and a first stage dirt collection chamber are closed and an open position in which the first stage cyclone chamber and the first stage dirt collection chamber are open, and a second cyclonic cleaning stage having a second end moveable between a closed position in which a plurality of second stage cyclone chambers and at least one second stage dirt collection chamber are closed and an open position in which the second stage cyclone chambers and the second stage dirt collection chamber are open.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/137,814, filed on Apr. 25, 2016, which is still pending, thedisclosure of which is incorporated herein by reference in its entirety.

FIELD

This disclosure relates generally to cyclone assemblies for surfacecleaning apparatus, and more specifically to cyclone assemblies thathave first and second cyclonic cleaning stages.

INTRODUCTION

Various types of surface cleaning apparatus are known, including uprightsurface cleaning apparatus, canister surface cleaning apparatus, sticksurface cleaning apparatus, hand carriable surface cleaning apparatus,and central vacuum systems.

Surface cleaning apparatus that use one or more cyclonic cleaning stagesto remove particulate matter (e.g. dust and dirt) from an airstream areknown.

A second cyclonic cleaning stage, which may comprise a plurality ofcyclones in parallel, may be provided downstream of a first cycloniccleaning stage and upstream of the suction motor. The second cycloniccleaning stage is typically provided to remove particulate matter fromthe airstream exiting the first cyclonic cleaning stage and was notremoved from the airstream by the first cyclonic cleaning stage.

Typically, second stage cyclones are effective at removing additionalparticulate matter from the airstream. However, a pre-motor filter isoften provided downstream of the first cyclonic cleaning stage andupstream of the suction motor to protect the suction motor by filteringout particulate matter from the airstream that was not removed from theairstream by either the first or second cyclonic cleaning stage.However, there may be one or more disadvantages associated withproviding a pre-motor filter. For example, the pre-motor filter maybecome clogged with particulate matter, requiring a user to clean and/orreplace the filter, a task a user may regard as undesirable.

SUMMARY

The following introduction is provided to introduce the reader to themore detailed discussion to follow. The introduction is not intended tolimit or define any claimed or as yet unclaimed invention. One or moreinventions may reside in any combination or sub-combination of theelements or process steps disclosed in any part of this documentincluding its claims and figures.

In accordance with one aspect of this disclosure, a cyclone assemblythat may be used as an air treatment member to remove particulate matter(e.g. dirt, dust) from an airflow includes a first cyclonic cleaningstage and a second cyclonic cleaning stage located downstream of thefirst cyclonic cleaning stage wherein the second cyclonic cleaning stageincludes a greater number of cyclone chambers than the first cycloniccleaning stage. The first and second cyclonic stages are configured toprovide reduced back pressure caused by air flow through the cyclonicstages. To this end, the cyclone chambers of the second cycloniccleaning stage may be taller than the cyclone stage(s) of the firstcyclonic cleaning stage.

In order to reduce backpressure through such a cyclone assembly, it ispreferred that the velocity of the airflow entering the first cycloniccleaning stage is approximately equal to the velocity of the airflowentering the second cyclonic cleaning stage. While the airflow velocitythrough the first stage air inlet is preferably approximately equal tothe airflow velocity through each of the second stage air inlets, theseparation characteristics of the first and second cyclonic cleaningstages may nonetheless be different. For example, if a second stagecyclone chamber has a smaller radius than the first stage cyclonechamber, particles entrained in the airflow in the second stage cyclonewill experience a greater centrifugal force than they experienced in thefirst stage cyclone, which may promote the dis-entrainment of smallerparticles from the airflow in the second cyclonic cleaning stage.

In an effort to achieve relatively equal airflow velocities (e.g., ±25%,±20%, ±15%, ±10%, ±5%, the total cross-sectional area of the airinlet(s) of the first cyclonic cleaning stage is preferablyapproximately equal to the total cross-sectional area of the secondstage air inlets (i.e. the sum of the cross-sectional areas of eachsecond stage cyclone chamber air inlet). If the first cyclonic cleaningstage comprises a single cyclone chamber, then the total cross-sectionalarea of the air inlet of the first cyclonic cleaning stage is preferablyapproximately equal to the total cross-sectional area of the secondstage air inlets.

However, due to boundary layer effects at the perimeter, the effectivecross-sectional area of an air inlet may be smaller than the physicaldimensions of the inlet. For example, for a rectangular air inlet ofheight H, width W, and assuming a constant boundary layer thicknessL_(B), the effective cross sectional area for the inlet may be estimatedas:Area_(Effective)=(H−(2×L _(B)))×(W−(2×L _(B)))=HW−2(HL _(B) +WL _(B)−2L_(B) ²).

If the second cyclonic cleaning stage has a larger number of secondstage cyclones than the first cyclonic cleaning stage, and therefore alarger number of air inlets, and the sum of the cross sectional areas ofthe first stage air inlets is equal to the sum of the cross sectionalareas of the second stage air inlets, then the sum of the effectivecross sectional areas of the first stage air inlets may be less than thesum of the effective cross sectional areas of the second stage airinlets. The reason for this is that the total effective cross-sectionalarea of the second stage air inlets may be reduced by a greater amountthan that of the first stage air inlet(s) as the boundary layerthickness at the perimeter of an inlet is typically not dependent on thearea of the inlet. To adjust for this imbalance, the totalcross-sectional area of the second stage air inlets, and optionally thecross-sectional area of each second stage air inlet, may be increased byabout 5 to 30%, preferably about 10 to 20%, and more preferably by about15% over what would be required to provide an approximately equal totalphysical inlet area for the second stage.

Also, it may be assumed that, generally, during each revolution within acyclone chamber, an air stream moves in the longitudinal directiontowards an end of the cyclone chamber by about the height of the cyclonechamber air inlet. For example, in a cyclone chamber that has alongitudinal height that is five times greater than the longitudinalheight of its air inlet, the air may be expected to rotate about fivetimes as it travels from the end of the cyclone chamber that has the airinlet to the opposite end of the cyclone chamber.

Accordingly, to provide first and second stage cyclones that have aboutthe same number of turns within their respective cyclone chambers, eachcyclone chamber preferably has a similar ratio of the longitudinalheight of its air inlet to the longitudinal height of the cyclonechamber. Thus, where the longitudinal height of the air inlet for eachsecond stage cyclone chamber is greater than the longitudinal height ofthe air inlet for the first stage cyclone chamber, the height of eachsecond stage cyclone chamber is preferably greater than the height ofeach first stage cyclone chamber.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage cyclone having a first stage cyclone chamber, each        first stage cyclone having a first stage longitudinal cyclone        axis about which the air rotates in the first stage cyclone        chamber, each first stage cyclone chamber having a height        extending between a first stage cyclone chamber air inlet and a        first stage cyclone dirt outlet; and    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of second        stage cyclones in parallel, each of the plurality of second        stage cyclones has a second stage cyclone chamber having a        second stage longitudinal cyclone axis about which the air        rotates in the second stage cyclone chamber, each second stage        cyclone chamber having a height extending between a second stage        cyclone chamber air inlet and a second stage cyclone dirt        outlet,    -   wherein the second cyclonic cleaning stage has a larger number        of second stage cyclones than the first cyclonic cleaning stage,        and wherein the height of each second stage cyclone chamber is        greater than the height of each first stage cyclone chamber.

In some embodiments, the second stage cyclone dirt outlets may beprovided in sidewalls of the second stage cyclones.

In some embodiments, the first and second stage longitudinal cycloneaxes may be generally parallel.

In some embodiments, the first and second stage cyclones may beinverted.

In some embodiments, some or all of the second stage cyclone chamber airinlets may have a height in a direction of the second stage longitudinalcyclone axis that is greater than a height of each first stage cyclonechamber air inlet in a direction of the first stage longitudinal cycloneaxis.

In some embodiments, the height of some or all of the second stagecyclone chamber air inlets may be 1.25 to 2.5 times greater than theheight of each first stage cyclone chamber air inlet.

In some embodiments, the height of each second stage cyclone chamber maybe greater than the height of each first stage cyclone chamber by atleast the height of the first stage cyclone chamber air inlet.Optionally, in some embodiments, each of the second stage cyclonechamber air inlets may have a height in a direction of the second stagelongitudinal cyclone axis that is 1.25 to 2.5 times greater than aheight of each first stage cyclone chamber air inlet in a direction ofthe first stage longitudinal cyclone axis.

In some embodiments, each of the second stage cyclone chamber air inletsmay have a width in a direction transverse to the second stagelongitudinal cyclone axis according to the following formula:W₂=W₁/N±15%, wherein W₂ is the width of the second stage cyclone inletsin a direction transverse to the second stage longitudinal cyclone axis;W₁ is the width of the first stage cyclone inlets in a directiontransverse to the first stage longitudinal cyclone axis; and, N is thenumber of second stage cyclones. Optionally, in some embodiments, someor all of the second stage cyclone chamber air inlets may have a heightin a direction of the second stage longitudinal cyclone axis that isgreater than a height of the first stage cyclone chamber air inlet in adirection of the first stage longitudinal cyclone axis. Optionally, insome embodiments, the height of some or all the second stage cyclonechamber air inlets may be 1.25 to 2.5 times greater than the height ofthe first stage cyclone chamber air inlet.

In some embodiments, each of the first and second stage cyclone chamberair inlets may have a cross sectional area and a total of the crosssectional areas of the second stage cyclone chamber air inlets may begreater than a total of the cross sectional area of the first stagecyclone chamber air inlets.

In some embodiments, the total of the cross sectional areas of thesecond stage cyclone chamber air inlets may be 1.1-2, 1.1-1.5 or 1.1-1.3times greater than the total of the cross sectional area of the firststage cyclone chamber air inlets.

In some embodiments, each of the first and second stage cyclone chamberair inlets has a cross sectional area and a total of the cross sectionalareas of the second stage cyclone chamber air inlets may be greater thana total of the cross sectional area of the first stage cyclone chamberair inlets.

In some embodiments, each of the first and second stage cyclone chambershas a cyclone chamber air outlet and each cyclone chamber air outlet hasa cross sectional area and a total of the cross sectional areas of thesecond stage cyclone chamber air outlets may be greater than a total ofthe cross sectional area of the first stage cyclone chamber air outlets.

In some embodiments, the total of the cross sectional areas of thesecond stage cyclone chamber air outlets may be 1.1-2, 1.1-1.5 or1.1-1.3 times greater than the total of the cross sectional area of thefirst stage cyclone chamber air outlets.

In some embodiments, the height of each first stage cyclone chamber maybe selected such that air rotates 2-4 times in each first stage cyclonechamber and the height of each second stage cyclone chamber may beselected such that air rotates 2-4 times in each second stage cyclonechamber.

In some embodiments, the height of each first and second stage cyclonechamber may be selected such that air rotates about 3 times in eachcyclone chamber.

In accordance with another aspect of this disclosure, at least a portionof, and preferably most or substantially all of a second stage dirtcollection region may be positioned longitudinally above and overlyingthe first stage cyclone chamber. Providing the second stage dirtcollection region in such a location may facilitate a more compactdesign of a two stage cyclone assembly.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage inverted cyclone having a first stage cyclone        chamber and an upper end;    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of inverted        second stage cyclones in parallel, each of the plurality of        second stage cyclones has a second stage cyclone chamber,    -   wherein the second cyclonic cleaning stage comprises a second        stage dirt collection region and at least a portion of the        second stage dirt collection region is positioned longitudinally        above the first stage cyclone chamber and overlying the first        stage cyclone chamber.

In some embodiments, the at least a portion of the second stage dirtcollection region may be positioned on the upper end.

In some embodiments, the second stage dirt collection region may beexternal to the second stage cyclones.

In some embodiments, the second stage dirt collection region maycomprise a plurality of second stage dirt collection chambers.

In some embodiments, each second stage cyclone chamber has a secondstage cyclone dirt outlet, each of which may be provided in a sidewallof one of the second stage cyclones.

In some embodiments, the first cyclonic cleaning stage has a first stagedirt collection region that may be external to the at least one firststage inverted cyclone and each first stage cyclone chamber has a firststage cyclone dirt outlet which may be provided in a sidewall of the atleast one first stage inverted cyclone.

In some embodiments, the cyclone assembly may further comprise anopenable lid which closes an upper end of the second stage cyclones andthe second stage dirt collection region wherein when the openable lid isin an open position, the upper end of the second stage cyclones and thesecond stage dirt collection region may be opened.

In some embodiments, the first cyclonic cleaning stage has a first stagedirt collection region that may be external to the at least one firststage inverted cyclone and the cyclone bin assembly has an upper endcomprising the second stage dirt collection region and the upper end maybe moveably to an open position in which the at least one first stageinverted cyclone and the first stage dirt collection region are open.

In some embodiments, when the upper end is in the open position thesecond stage dirt collection region may be closed.

In some embodiments, when the upper end is in the open position thesecond stage cyclones may also be opened.

In some embodiments, the cyclone assembly further comprises an openablelid which may close an upper end of the second stage dirt collectionregion wherein when the openable lid is in an open position, the upperend of the second stage dirt collection region may be opened and theopenable lid may be openable when the upper end is in the open position.

In some embodiments, when the upper end comprises an upper openable lidwhich closes an upper end of the second stage dirt collection region anda lower wall, the lower wall may comprise an upper end wall of the atleast one first stage inverted cyclone.

In accordance with another aspect of this disclosure, an upstreampre-motor filter chamber or manifold may be positioned facing, e.g.,below, the second cyclonic cleaning stage and each of the second stagecyclone air outlets may have an outlet extend to an opening in a wall ofthe chamber or manifold. An advantage of this design is that fewerconduit walls and/or ducting may be required to direct airflow from thesecond cyclonic cleaning stage towards the pre-motor filter, which maysimplify the design and/or construction of the cyclone assembly and/orsurface cleaning apparatus, and/or may reduce backpressure through thesurface cleaning apparatus.

In accordance with this broad aspect, there is provided a cycloneassembly for a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage cyclone, which may be an inverted cyclone, having a        first stage cyclone chamber and a first stage cyclone air        outlet;    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of second        stage cyclones in parallel, each of the plurality of second        stage cyclones may be an inverted cyclone and may each have a        second stage cyclone chamber, each of the second stage cyclones        having a second stage cyclone air outlet; and    -   (c) a pre-motor filter chamber, which may be positioned below        the second cyclonic cleaning stage, wherein each of the second        stage cyclone air outlets has an outlet end in a wall forming an        upstream pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning stage may be removablefrom the pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning may have an openablebottom wall wherein the second stage cyclones are opened when theopenable bottom wall is in an open position.

In some embodiments, the first cyclonic cleaning stage may have a firststage dirt collection region that is external to the at least one firststage inverted cyclone and the first stage dirt collection region may beopened when the openable bottom wall is in an open position.

In some embodiments, the second cyclonic cleaning stage may comprise asecond stage dirt collection region and the cyclone assembly may furthercomprise an openable lid which closes an upper end of the second stagedirt collection region wherein when the openable lid is in an openposition, the upper end of the second stage dirt collection region maybe opened.

In some embodiments, the cyclone assembly may further comprise a headerdownstream of the first stage cyclone air outlet and upstream of thesecond stage cyclones wherein the header is positioned between the firstthe first stage cyclone air outlet and the pre-motor filter chamber.

In some embodiments, the second cyclonic cleaning may have an openablebottom wall wherein the second stage cyclones and the header are openedwhen the openable bottom wall is in an open position.

In some embodiments, the first cyclonic cleaning stage may have a firststage dirt collection region that is external to the at least one firststage inverted cyclone and the first stage dirt collection region may beopened when the openable bottom wall is in an open position.

In accordance with another aspect of this disclosure, a releasemechanism may be provided which is moveable to two open positionswherein, in a first open position, a first lock is moved to an unlockedposition and in a second open position, a second lock is moved to anunlocked position. An advantage of this design is that the same actuatormay be used to unlock an upper end of a cyclone assembly that houses asecond stage dirt collection area and to open an upper lid that opensthe second stage dirt collection area.

In accordance with another aspect of this disclosure, a compact cycloneassembly which has two cyclonic stages, and may have reducedbackpressure thereacross, is provided. In accordance with this aspect, acyclone assembly may have first and second cyclonic stages wherein theinlet to the cyclones of the second cyclonic stage are proximate to theoutlet of a single cyclone of the first cyclonic stage (e.g., axiallyspaced and radially spaced therefrom). The dirt collection region forthe second stage cyclone may be centrally located (e.g., a plurality ofsecond stage cyclones may surround the dirt collection region).Accordingly, the dirt collection region may be axially spaced from theoutlet of a single cyclone of the first cyclonic stage and a headerupstream from the air inlets of the cyclones of the second cyclonicstage may be provided between the dirt collection region and the outletof a single cyclone of the first cyclonic stage. An advantage of thisdesign is that air may exit the first cyclonic stage and directly entera header for the second cyclonic stage thereby reducing backpressurethrough the cyclonic assembly. Another advantage is that by placing thesecond stage dirt collection region centrally between the second stagecyclones, the second stage dirt collection region and the second stagecyclones may be opened concurrently.

In accordance with this broad aspect, there is provided cyclone assemblyfor a surface cleaning apparatus comprising:

-   -   (a) a first cyclonic cleaning stage comprising at least one        first stage cyclone having a first stage cyclone chamber and a        first stage dirt collection chamber external to the cyclone        chamber, the first cyclonic cleaning stage having a longitudinal        axis and first and second longitudinally spaced apart ends        wherein the first end is moveable between a closed position in        which the first stage cyclone chamber and the first stage dirt        collection chamber are closed and an open position in which the        first stage cyclone chamber and the first stage dirt collection        chamber are open; and,    -   (b) a second cyclonic cleaning stage downstream from the first        cyclonic cleaning stage and comprising a plurality of second        stage cyclones in parallel and at least one second stage dirt        collection chamber external to the cyclone chambers, wherein        each of the plurality of second stage cyclones has a second        stage cyclone chamber, the second cyclonic cleaning stage having        a longitudinal axis and first and second longitudinally spaced        apart ends,    -   wherein the first end of the second cyclonic cleaning stage is        proximal to the second end of the first cyclonic cleaning stage        and the second end of the second cyclonic cleaning stage is        axial spaced from the first end of the second cyclonic cleaning        stage, and    -   wherein the second end of the second cyclonic cleaning stage is        moveable between a closed position in which the second stage        cyclone chambers and the at least one second stage dirt        collection chamber are closed and an open position in which the        second stage cyclone chambers and the at least one second stage        dirt collection chamber are open.

In some embodiments, the at least one second stage dirt collectionchamber may be centrally positioned, in a transverse direction, in thesecond cyclonic cleaning stage.

In some embodiments, the second stage cyclone chambers may be positionedaround the at least one second stage dirt collection chamber.

In some embodiments, the at least one second stage dirt collectionchamber may comprise a plurality of second stage dirt collectionchambers.

In some embodiments, the at least one second stage dirt collectionchamber may comprise a single second stage dirt collection chamber.

In some embodiments, the at least one second stage dirt collectionchamber may be axially spaced from and facing an air outlet of the firststage cyclone chamber.

In some embodiments, the first end of the second cyclonic cleaning stagemay be axially spaced from and face the second end of the first cycloniccleaning stage.

In some embodiments, the first stage cyclone chamber may have a sidewall dirt outlet.

In some embodiments, the first stage cyclone chamber may have an airoutlet at the second end of the first cyclonic cleaning stage and thedirt outlet may be provided at the second end of the first cycloniccleaning stage.

In some embodiments, the first stage cyclone chamber may have an airinlet at the second end of the first cyclonic cleaning stage.

In some embodiments, the second stage cyclone chambers may have airinlets at the first end of the second cyclonic cleaning stage.

In some embodiments, the second stage cyclone chambers may have airoutlets at the second end of the second cyclonic cleaning stage.

In some embodiments, the air inlets of the second stage cyclone chambersmay be centrally positioned, in a transverse direction.

In some embodiments, the air inlets of the second stage cyclone chambersmay be axially spaced from and face an air outlet of the first cycloniccleaning stage.

In some embodiments, the first end of the first cyclonic cleaning stageand the second end of the second cyclonic cleaning stage may be providedat longitudinally opposed ends of the cyclone bin assembly.

In some embodiments, the second stage cyclone chambers may have sidewall dirt outlets.

In some embodiments, the second stage cyclone chambers may have airoutlets at the second end of the second cyclonic cleaning stage and thedirt outlets may be provided at the second end of the second cycloniccleaning stage.

In some embodiments, the first stage cyclone chamber may have an airoutlet at the second end of the first cyclonic cleaning stage and thefirst stage cyclone chamber may have a dirt outlet provided at thesecond end of the first cyclonic cleaning stage and wherein the secondstage cyclone chambers may have air outlets at the second end of thesecond cyclonic cleaning stage and the second stage cyclone chambers mayhave dirt outlets provided at the second end of the second cycloniccleaning stage.

In some embodiments, the second stage cyclone chambers may have airinlets at the first end of the second cyclonic cleaning stage.

In some embodiments, the air inlets of the second stage cyclone chambersmay be centrally positioned, in a transverse direction.

A pre-motor filter is typically provided downstream of the cycloniccleaning stages and upstream of the suction motor, to preventparticulate matter that is not removed from the airstream by thecyclonic cleaning stages from being drawn into the suction motor.Otherwise, this unremoved particulate matter may cause damage to (orotherwise impair) the suction motor. While the use of a pre-motor filtermay be effective at protecting the suction motor, there may be one ormore disadvantages. For example, the pre-motor filter may become cloggedwith particulate matter, requiring a user to clean and/or replace thefilter, a task a user may regard as undesirable.

In some embodiments disclosed herein, all or substantially all of thedirt entrained in the air exiting the first cyclonic cleaning stage maybe removed from the airflow by the second cyclonic cleaning stage. Thismay, for example, obviate the need to provide a pre-motor filter in thesurface cleaning apparatus.

It will be appreciated by a person skilled in the art that an apparatusor method disclosed herein may embody any one or more of the featurescontained herein and that the features may be used in any particularcombination or sub-combination.

These and other aspects and features of various embodiments will bedescribed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the described embodiments and to show moreclearly how they may be carried into effect, reference will now be made,by way of example, to the accompanying drawings in which:

FIG. 1 is a perspective view of a surface cleaning apparatus comprisinga cyclone assembly in accordance with one embodiment;

FIG. 2 is a perspective view of the cyclone assembly of FIG. 1;

FIG. 3 is a top perspective view of the cyclone assembly of FIG. 2;

FIG. 4 is a top perspective view of the cyclone assembly of FIG. 2, withan upper lid in an open position;

FIG. 5 is a top perspective view of the cyclone assembly of FIG. 2, withan upper end in an open position and the upper lid in a closed position;

FIG. 6 is a perspective view of the cyclone assembly of FIG. 5, withportions of the outer wall removed for clarity;

FIG. 7 is a bottom perspective view of the cyclone assembly of FIG. 2;

FIG. 8 is a bottom perspective view of the cyclone assembly of FIG. 2,with a bottom in an open position;

FIG. 9 is a cross-section view of the surface cleaning apparatus of FIG.1;

FIG. 10 is an enlarged view of the lower portion of FIG. 9;

FIG. 11 is a section view of the cyclone assembly and suction motorhousing of the surface cleaning apparatus of FIG. 8, taken along line11-11 shown in FIG. 1;

FIG. 12 is a cross-section view of the cyclone assembly of FIG. 2, takenalong line 12-12 shown in FIG. 2;

FIG. 13 is a section view of the cyclone assembly of FIG. 2, taken alongline 13-13 shown in FIG. 2;

FIG. 14 is a cross-section view of the cyclone assembly of FIG. 2, takenalong line 14-14 shown in FIG. 3, with a portion of the lower wall ofthe first stage cyclone removed to reveal a plurality of second stagecyclone chamber air inlets;

FIG. 15 is a top view of the bottom of the cyclone assembly of FIG. 2;

FIG. 16 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 16-16 shown in FIG. 1, with a release mechanismin a neutral position;

FIG. 17 is a top view of the enlarged portion of FIG. 16;

FIG. 18 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 16-16 shown in FIG. 1, with the releasemechanism in a first unlocked position;

FIG. 19 is a cross-section view of the surface cleaning apparatus ofFIG. 1, with the release mechanism in a first unlocked position;

FIG. 20 is a cross-section view of the surface cleaning apparatus ofFIG. 1, taken along line 20-20 shown in FIG. 1, with the releasemechanism in a second unlocked position;

FIG. 21 is a top view of the enlarged portion of FIG. 20, with therelease mechanism in a neutral position;

FIG. 22 is a cross-section view of the surface cleaning apparatus ofFIG. 1, with the release mechanism in the second unlocked position;

FIG. 23 is a cross-section view of a cyclone assembly and a suctionsource in accordance with another embodiment;

FIG. 24 is a cross-section view of the cyclone assembly of FIG. 23, witha first end of a first cyclonic cleaning stage in an open position andwith a second end of a second cyclonic cleaning stage in an openposition;

FIG. 25 is an axial cross-section view of the cyclone assembly of FIG.23, taken along line 25-25;

FIG. 26 is an axial cross-section view of the cyclone assembly of FIG.23, taken along line 26-26; and,

FIG. 27 is an end view of the second cyclonic cleaning stage of thecyclone assembly of FIG. 23, with the second end of a second cycloniccleaning stage removed to reveal a plurality of second stage cyclonechambers and a plurality of second stage dirt collection chambers.

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatuses of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Various apparatuses, methods and compositions are described below toprovide an example of an embodiment of each claimed invention. Noembodiment described below limits any claimed invention and any claimedinvention may cover apparatuses and methods that differ from thosedescribed below. The claimed inventions are not limited to apparatuses,methods and compositions having all of the features of any oneapparatus, method or composition described below or to features commonto multiple or all of the apparatuses, methods or compositions describedbelow. It is possible that an apparatus, method or composition describedbelow is not an embodiment of any claimed invention. Any inventiondisclosed in an apparatus, method or composition described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicant(s), inventor(s) and/or owner(s) do not intend to abandon,disclaim, or dedicate to the public any such invention by its disclosurein this document.

Furthermore, it will be appreciated that for simplicity and clarity ofillustration, where considered appropriate, reference numerals may berepeated among the figures to indicate corresponding or analogouselements. In addition, numerous specific details are set forth in orderto provide a thorough understanding of the example embodiments describedherein. However, it will be understood by those of ordinary skill in theart that the example embodiments described herein may be practicedwithout these specific details. In other instances, well-known methods,procedures, and components have not been described in detail so as notto obscure the example embodiments described herein. Also, thedescription is not to be considered as limiting the scope of the exampleembodiments described herein.

In the examples discussed herein, the surface cleaning apparatus withwhich the cyclone assembly is used is an upright vacuum cleaner. Inalternative embodiments, the surface cleaning apparatus may be anothersuitable type of surface cleaning apparatus, such as a canister typevacuum cleaner, a hand vacuum cleaner, a stick vac, a wet-dry typevacuum cleaner, a carpet extractor, and the like.

General Description of a Surface Cleaning Apparatus

Referring to FIG. 1, a surface cleaning apparatus is shown generally as10. The surface cleaning apparatus includes a surface cleaning head 12and an upper portion 14 that is movably and drivingly connected to thesurface cleaning head 12. The surface cleaning head 12 may be supportedby any suitable support members, such as, for example wheels and/orrollers, to allow the surface cleaning head to be moved across a flooror other surface being cleaned. The support members (e.g., wheels) maybe of any suitable configuration, and may be attached to any suitablepart of the surface cleaning apparatus, including, for example, thesurface cleaning head and/or the upper portion.

The surface cleaning apparatus 10 includes a dirty air inlet 16, a cleanair outlet 18 and an air flow path or passage extending therebetween(See FIGS. 9-11). In the illustrated example, the air flow path includesat least one flexible air flow conduit member (such as a hose 15 orother flexible conduit). Alternatively, the air flow path may be formedfrom rigid members. A cyclone assembly 100 and at least one suctionmotor are provided in the air flow path. Preferably, the cycloneassembly is provided upstream from a suction unit 20 that contains thesuction motor(s), but alternatively may be provided downstream from thesuction motor(s). In addition to the cyclone assembly, the surfacecleaning apparatus may also include one or more pre-motor filters(preferably positioned in the air flow path between the cyclone assemblyand the suction motor) and/or one or more post-motor filters (positionedin the air flow path between the suction motor and the clean airoutlet).

General Description of a Cyclone Assembly

FIGS. 2-8 and 12-15 illustrate an embodiment of a cyclone assembly,referred to generally as 100. Cyclone assembly 100 may be used as an airtreatment member to remove particulate matter (e.g. dirt, dust) from anair flow. Preferably, the cyclone assembly is removable from the surfacecleaning apparatus. Providing a detachable cyclone assembly 100 mayallow a user to carry the cyclone assembly 100 to a garbage can foremptying, without needing to carry or move the rest of the surfacecleaning apparatus 10. Preferably, the cyclone assembly is removable asa closed module, which may help prevent dirt and debris from spillingout of the cyclone assembly 100 during transport.

As shown in FIG. 2, the cyclone assembly 100 has a lower end 102, anupper end 104, and an outer sidewall 108. Preferably, an assembly handle106 is provided at the upper end 104. The assembly handle 106 mayfacilitate carrying of the cyclone assembly when it is detached from thesurface cleaning apparatus 10.

Referring to FIGS. 4-8 and 12-15, cyclone assembly 100 includes a firstcyclonic cleaning stage and a second cyclonic cleaning stage locateddownstream of the first cyclonic cleaning stage. The first cycloniccleaning stage includes a first stage cyclone chamber 110 that extendsalong a cyclone axis 115 and includes a generally cylindrical sidewall111 extending between a lower end wall 113 and an intermediate wall 140(which is an upper end wall of the cyclone chamber 110). In theillustrated embodiment, the first stage cyclone chamber 110 is arrangedin a generally vertical, inverted cyclone orientation. Alternatively,the first stage cyclone chamber can be provided in another orientation,for example as a horizontal or inclined cyclone and may be of anycyclone construction. Alternately, or in addition, the first cycloniccleaning stage may comprise a plurality of cyclone chambers.

In the illustrated embodiment, the first stage cyclone chamber 110includes a first stage cyclone air inlet 112 and a first stage cycloneair outlet 114.

First stage cyclone chamber 110 also includes at least one dirt outlet118, through which dirt and debris that is separated from the air flowcan exit the cyclone chamber 110. While it is preferred that most or allof the dirt exit the first stage cyclone chamber via the dirt outlet118, some dirt may settle on the bottom end wall 113 of the cyclonechamber 110 and/or may be entrained in the air exiting the first stagecyclone chamber via the air outlet 114.

In the illustrated example, the first stage cyclone dirt outlet 118 isin the form of a slot bounded by the cyclone side wall 111 and the uppercyclone end wall 140, and is located toward the upper end of the cyclonechamber 110. Alternatively, the dirt outlet may be of any other suitableconfiguration, and may be provided at another location in the cyclonechamber, including, for example as an annular gap between the sidewalland an end wall of the cyclone chamber or an arrestor plate or othersuitable member.

Preferably, the first stage cyclone air inlet 112 is located toward oneend of the cyclone chamber 110 (the lower end in the illustratedexample) and may be positioned adjacent the corresponding cyclonechamber end wall 113. Alternatively, the cyclone air inlet 112 may beprovided at another location within the first stage cyclone chamber 110.Preferably, the air inlet 112 is positioned so that air flowing throughthe inlet and into the first stage cyclone chamber is travellinggenerally tangentially relative to, and preferably adjacent, thesidewall 111 of the cyclone chamber 110.

The cross-sectional shape of the air inlet 112 can be any suitableshape. In the illustrated example of FIG. 12, the air inlet has across-sectional shape that is generally rectangular (e.g., it hasrounded corners and can be referred to as a rounded rectangle) having aheight H_(I) ₁ in the longitudinal direction (i.e. parallel to cycloneaxis 115) and a width W_(I) ₁ in a transverse direction cyclone axis115. The cross-sectional area of the air inlet 112 can be referred to asthe cross-sectional area or flow area of the first stage cyclone airinlet 112. Alternatively, instead of being a rounded rectangle, thecross-sectional shape of the air inlet may be another shape, including,for example, round, oval, square and rectangular.

Referring to FIG. 12, the first stage cyclone chamber 110 has a heightH_(C) ₁ in the longitudinal direction (i.e. parallel to cyclone axis115). The height of the first stage cyclone chamber 110 is preferablyselected such that air entering the cyclone chamber via inlet 112 isexpected to rotate approximately 3 to 6 times, 3 to 5 times, 2 to 4times or three-and-a-half times in the first stage cyclone chamber priorto exiting the cyclone chamber via outlet 114.

In general, it may be assumed that the airflow against the cyclonechamber sidewall as it progresses around the cyclone chamber maintains adegree of cohesion, and that during each revolution within a cyclonechamber, an air stream moves in the longitudinal direction towards anend of the cyclone chamber by a distance approximately equal to theheight of the cyclone chamber air inlet. For example, in a cyclonechamber that has a longitudinal height that is five times greater thanthe longitudinal height of its air inlet, the resulting cyclone may beexpected to rotate about five times as it travels from the end of thecyclone chamber that has the air inlet to the opposite end of thecyclone chamber.

Thus, in order to promote the formation of a cyclone that is expected torotate about three-and-a-half times in the first stage cyclone chamber110, the height H_(C) ₁ of the first stage cyclone chamber 110 may bebetween 3 and 4 times, the height H_(I) ₁ of the first stage cyclone airinlet 112.

Air can exit the first stage cyclone chamber 110 via the first stage airoutlet 114. Preferably, the cyclone air outlet is positioned in one ofthe cyclone chamber end walls and, in the example illustrated, ispositioned in the same end as the air inlet 112 and air inlet 112 may bepositioned adjacent or at the end wall 113. In the illustratedembodiment the air outlet 114 is generally circular in cross-sectionalshape. Preferably, the cross-sectional or flow area of the first stagecyclone air outlet 114 is generally equal to the flow area of the firststage cyclone air inlet 112. In the illustrated example, the cyclone airoutlet 114 comprises a vortex finder 116.

Air exiting the first stage air outlet 114 may be directed into achamber or manifold 117. From there, the air is directed into the secondcyclonic cleaning stage. The second cyclonic cleaning stage includes aplurality of second stage cyclone chambers 120 arranged in parallel. Inthe illustrated embodiment, six second stage cyclone chambers are shown,referred to as 120 a, 120 b, 120 c, 120 d, 120 e, and 120 f,respectively.

In the illustrated embodiment, each second stage cyclone chamber 120 isarranged in a generally vertical, inverted cyclone orientation.Alternatively, the second stage cyclone chambers can be provided inanother orientation, for example as horizontal or inclined cyclones andmay be of any cyclone construction.

In the illustrated embodiment, each second stage cyclone chamber extendsalong a respective cyclone axis 125 (see e.g. FIGS. 5 and 13) andextends between a lower end wall or bottom 130 and an upper end wall150. In the illustrated embodiment, each second stage cyclone chamber isbounded by a lower sidewall 121 and an upper sidewall extension 141.

In the illustrated embodiment, each second stage cyclone chamber 120includes a second stage cyclone air inlet 122 and a second stage cycloneair outlet 124. Each second stage cyclone chamber 120 also includes atleast one dirt outlet 128, through which dirt and debris that isseparated from the air flow can exit the cyclone chamber 120. While itis preferred that most or all of the dirt entrained in the air exitingthe first cyclonic cleaning stage exits the second stage cyclonechambers via the dirt outlets 128, some dirt may settle on the bottomend wall 130 of the cyclone chambers 120 and/or may be entrained in theair exiting the second stage cyclone chambers via the air outlets 124.

In some embodiments, all or substantially all of the dirt entrained inthe air exiting the first cyclonic cleaning stage may be removed fromthe airflow by the second cyclonic cleaning stage. This may, forexample, obviate the need to provide a pre-motor filter in the surfacecleaning apparatus 10.

In the illustrated example, each second stage cyclone dirt outlet 128 isin the form of a slot bounded by the cyclone side wall 121 and the uppercyclone end wall 150, and is located toward the upper end of the cyclonechamber 120. Alternatively, the dirt outlet may be of any other suitableconfiguration, and may be provided at another location in the cyclonechamber, including, for example as an annular gap between the sidewalland an end wall of the cyclone chamber or an arrestor plate or othersuitable member.

Preferably, each second stage cyclone air inlet 122 is located towardone end of the cyclone chamber 120 (the lower end in the illustratedexample) and may be positioned adjacent the corresponding cyclonechamber end wall 130. Alternatively, the cyclone air inlet 122 may beprovided at another location within the second stage cyclone chamber120. Preferably, each air inlet 122 is positioned so that air flowingthrough the inlet and into a second stage cyclone chamber is travellinggenerally tangentially relative to, and preferably adjacent, thesidewall 121 of the cyclone chamber 120.

The cross-sectional shape of the air inlet 122 can be any suitableshape. In the illustrated example each air inlet has a cross-sectionalshape that is generally rectangular (rounded rectangular), having aheight H_(I) ₂ in the longitudinal direction (i.e. parallel to cycloneaxis 125) and a width W_(I) ₂ in a transverse direction. The totalcross-sectional area of the second stage air inlets (i.e. the sum of thecross-sectional areas of each inlet 122 a-f) can be referred to as thetotal cross-sectional area or total flow area of the second cycloniccleaning stage.

Referring to FIG. 12, each second stage cyclone chamber 120 has a heightH_(C) ₂ in the longitudinal direction (i.e. parallel to cyclone axis125). The height of each second stage cyclone chamber 120 is preferablyselected such that air entering the cyclone chambers via inlets 122 isexpected to rotate approximately 3 to 6 times, 3 to 5 times, 2 to 4times or three-and-a-half times in each second stage cyclone chamberprior to exiting the cyclone chamber via outlet 124. For example, theheight H_(C) ₂ of a second stage cyclone chamber 120 may be between 3and 4 times, the height H_(I) ₂ of a second stage cyclone air inlet 122.

Air can exit each second stage cyclone chambers 120 via a second stageair outlet 124 provided for each cyclone chamber 120. Preferably, thecyclone air outlets 124 a-f are positioned in one of the end walls ofeach cyclone chamber 120 and, in the example illustrated, are positionedin the same ends as the air inlets 122 a-f. In the illustratedembodiment the air outlets 124 a-f are generally circular incross-sectional shape. Preferably, the cross-sectional or flow area ofeach second stage cyclone air outlet 124 is generally equal to the flowarea of the first stage cyclone air inlet 112 for its respective cyclonechamber. In the illustrated example, each cyclone air outlet 124comprises a vortex finder 126.

Height of Each Second Stage Cyclone Chamber Greater than the Height ofEach First Stage Cyclone Chamber

The following is a description of the sizing of a second stage cyclonecompared to a first stage cyclone that may be used by itself in anysurface cleaning apparatus or in any combination or sub-combination withany other feature or features disclosed herein including the positioningof the dirt collection region for second stage cyclones, a dual openinglatching mechanism and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In order to reduce backpressure through the cyclone assembly 100, it ispreferred that the velocity of the airflow entering the first cycloniccleaning stage is approximately equal to the velocity of the airflowentering the second cyclonic cleaning stage. That is, the airflowvelocity through the first stage cyclone air inlet 112 may beapproximately equal to the airflow velocity through each of the secondstage cyclone air inlets 122.

In an effort to achieve relatively equal airflow velocities, cycloneassembly 100 may be dimensioned so that the total cross-sectional areaof the air inlet for the first cyclonic cleaning stage (i.e. thecross-sectional area of the air inlet 112 in the illustrated example) isapproximately equal to the total cross-sectional area of the secondstage air inlets (i.e. the sum of the cross-sectional areas of eachinlet 122 a-f).

However, due to boundary layer effects at the perimeter of the inlet,the effective cross-sectional area of each air inlet 112, 122 may besmaller than the physical dimensions of the inlet. For example, aboundary layer having a thickness of about 0.005 to 0.010 inches mayform around the perimeter of each air inlet, reducing the effectivecross-sectional or flow area of that inlet. For example, for arectangular air inlet of height H, width W, and assuming a constantboundary layer L_(B), the effective cross sectional area for the inletmay be estimated as:Area_(Effective)=(H−(2×L _(B)))×(W−(2×L _(B)))=HW−2(HL _(B) +WL _(B)−2L_(B) ²).

Where the second cyclonic cleaning stage has a larger number of secondstage cyclones than the first cyclonic cleaning stage, as in theillustrated example, the total effective cross-sectional area of thesecond stage air inlets 122 may be reduced by a greater amount than thatof the first stage air inlet 112 (as the boundary layer thickness at theperimeter of an inlet is typically not dependent on the area of theinlet). To adjust for this imbalance, the cross-sectional area of eachsecond stage air inlet 122 is preferably increased by about 10 to 30%,and more preferably by about 15% over what would be required to providean approximately equal physical inlet area to air inlet 112. This may beachieved by varying the width and/or height of the second stage airinlets and preferably varying at least the height of the second stageair inlets. For example, the height of the second stage air inlets maybe increased by about 10 to 30%, and more preferably by about 15%.

While the airflow velocity through the first stage cyclone air inlet 112is preferably approximately equal to the airflow velocity through eachof the second stage cyclone air inlets 122, the separationcharacteristics of the first and second cyclonic cleaning stages maynonetheless be different. For example, since the second stage cyclonechambers 120 each have a smaller radius than the first stage cyclonechamber 110, particles entrained in the airflow in the second stagecyclones will experience a greater centrifugal force than theyexperienced in the first stage cyclone, which may promote thedis-entrainment of smaller particles from the airflow in the secondcyclonic cleaning stage.

In accordance with one feature, the height of each second stage cyclonechamber may be greater than the height of the first stage cyclonechamber. An example of such an arrangement is shown in FIGS. 4-6 and9-13.

Since the second stage cyclone chambers 120 each have a smaller radiusthan the radius of the first stage cyclone chamber 110, and since thewidth of an air inlet to a cyclone chamber is preferably a function ofthe cyclone chamber diameter, each second stage cyclone air inlet 122preferably has a narrower width than that of the first stage inlet 112.For example, an air stream entering a cyclone chamber may more or lessmaintain the same width as it travels through the cyclone chamber.Therefore, the radius of a cyclone chamber may be determined based onthe width of the air stream (the width of the air inlet) and the widthrequired for the return air steam travelling to the cyclone chamber airoutlet (e.g., the width of a vortex finder). Therefore the radius of acyclone chamber may be approximately equal to the width of the cyclonechamber air inlet, the width of the wall of the vortex finder and halfthe diameter of the vortex finder.

In certain preferred embodiments, without taking into account thedecreased flow area due to boundary layer effects, the width W_(I) ₂ foreach inlet 122 a-f may be within about +/−15% of the width W_(I) ₁ forinlet 112 divided by the number of second stage cyclone chambers. Forexample, in the illustrated embodiment, there are six second stagecyclone chambers 120 a-f, so the width W_(I) ₂ for each inlet 122 a-f ispreferably about

$\frac{W_{I_{1}}}{6} \pm {15{\%.}}$

As discussed above, the total cross-sectional area of the second stageair inlets (e.g. the sum of the cross-sectional areas of each inlet 122a-f) may be about 10-30% greater than the total cross-sectional area ofthe first cyclonic cleaning stage (e.g. the cross-sectional area of theair inlet 112), so that the effective flow area of the second cycloniccleaning stage is approximately equal to the effective flow area of thefirst cyclonic cleaning stage, after taking boundary layer effects atthe air inlets into account.

In order to determine the height H_(I) ₂ for each inlet 122, the radiusof the second stage cyclones may be first determined based on, e.g., thecentrifugal forces to be imposed on an air stream travelling therein.The width of the cyclone chamber air inlet 122 may then be determined tobe approximately equal to the radial thickness available in the cyclonechamber in which the air stream will rotate. Finally, the height H_(I) ₂for each inlet 122 may be determined based on the cross sectional arearequired to provide a cross-sectional flow area (taking into accountboundary layer losses) that is approximately equal to thecross-sectional flow area of the first stage cyclone air inlet (takinginto account boundary layer losses).

In certain other preferred embodiments, the height H_(I) ₂ of eachsecond stage cyclone chamber air inlet 122 is between about 1.25 to 2.5,1.25 to 2, 1.25 to 1.75 times greater than the height H_(I) ₁ of theinlet 112.

As noted above, the height H_(C) ₂ of a second stage cyclone chamber 120is preferably between 3 to 6, 3 to 5, 3 to 4 and may be about 3.5 timesthe height H_(I) ₂ of a second stage cyclone air inlet 122, and theheight H_(C) ₁ of the first stage cyclone chamber 110 is preferablybetween 3 to 6, 3 to 5, 3 to 4 and may be about 3.5 times the heightH_(I) ₁ of the first stage cyclone air inlet 112. Thus, since the heightH_(I) ₂ for each inlet 122 is preferably greater than H_(I) ₁ , theheight H_(C) ₂ of each second stage cyclone chamber 120 is preferablygreater than the height H_(C) ₁ of the first stage cyclone chamber 110.

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the second stage cyclone chambersdisclosed herein and that, in those embodiments, the second stagecyclone chambers may be of various constructions and that in thoseembodiments any second stage cyclone chamber known in the art may beused.

Dirt Collection Region for Second Stage Cyclones Positioned Above andOverlying the First Stage Cyclone

The following is a description of the positioning of the dirt collectionregion for second stage cyclones that may be used by itself in anysurface cleaning apparatus or in any combination or sub-combination withany other feature or features disclosed herein including the sizing of asecond stage cyclone compared to a first stage cyclone, a dual openinglatching mechanism and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In accordance with one feature, at least a portion of, and preferablymost or substantially all of a second stage dirt collection region maybe positioned longitudinally above and overlying the first stage cyclonechamber. In such an embodiment, this preferred location for the secondstage dirt collection region may facilitate a more compact design of thecyclone assembly 100.

Referring to FIG. 11, a first stage dirt collection chamber 119 is incommunication with dirt outlet 118 to collect the dirt and debris as itexits first stage cyclone chamber 110. Dirt collection chamber 119 maybe of any suitable configuration. Referring to FIGS. 5 and 13, in theillustrated example, the dirt collection chamber 119 is bounded by outersidewall 108, first stage cyclone side wall 111, lower end wall 130, andintermediate wall 140.

As shown in FIGS. 9 and 10, in use air enters the first stage cyclonechamber 110 via air inlet 112 and exits the chamber 110 via air outlet114, while separated dirt and debris exits the cyclone chamber 110 viadirt outlet 118, where it collects in the first stage dirt collectionchamber 119.

To help facilitate emptying the dirt collection chamber 119, at leastone of or both of the end walls 130, 140 may be openable. Preferably,end wall 130 is moveable between a closed position (FIG. 13 and FIG. 7)and an open position (FIG. 8). When the end wall 130 is in the openposition, the first stage dirt collection chamber 119 and the manifold117 may be emptied concurrently. In addition, the second cyclonechambers are also opened so that the second cyclone chambers may also beconcurrently openable. Optionally, it will be appreciated that thesecond stage cyclone chambers need not be opened, e.g., if the lowerends of the second stage cyclone chambers are not moveable with end wall130. Accordingly, the lower end walls of the dirt collection chamber 119and/or the cyclone chamber 110 and/or the second stage cyclone chambers120 need not be integral with each other, and the dirt collectionchamber 119 and/or the cyclone chamber 110 and/or the second stagecyclone chambers 120 may be openable independently or in asub-combination, e.g., the dirt collection chamber 119 and the cyclonechamber 110 may be openable independently of the second stage cyclonechambers 120 or the dirt collection chamber 119 and the second stagecyclone chambers 120 may be openable independently of the cyclonechamber 110.

End wall 130 is preferably configured so that when it is in the closedposition, the upper surface 132 cooperatively engages a lower surface ofone or more of the sidewalls 108, 111, and 121 a-f. For example, asshown in

FIGS. 8 and 15, the upper surface 132 may have one or more channels orgrooves 138 configured to receive the ends of sidewalls 108, 111, and121 a-f when the end wall 130 is in the closed position. Optionally, oneor more sealing or gasketing elements may be provided between groove(s)138 and the sidewall ends. Alternatively, the upper surface 132 may berelatively planar, and configured to abut the sidewalls 108, 111, and121 a-f, with or without gasketing elements.

Referring to FIG. 5, in the illustrated example, intermediate wall 140acts as an upper end wall for both dirt collection chamber 119 and firststage cyclone chamber 110. Wall 140 is moveable between a closedposition (FIG. 13) and an open position (FIG. 5). When the intermediatewall 140 is in the open position, the first stage cyclone chamber 110,the first stage dirt collection chamber 119, and the second stagecyclone chambers 120 a-f can be emptied concurrently. Alternatively, theupper end walls of the dirt collection chamber 119 and/or the cyclonechamber 110 and/or the second stage cyclone chambers 120 need not beintegral with each other, and the dirt collection chamber 119 and/or thecyclone chamber 110 and/or the second stage cyclone chambers 120 may beopenable independently or in a sub-combination, e.g., the dirtcollection chamber 119 and the cyclone chamber 110 may be openableindependently of the second stage cyclone chambers 120 or the dirtcollection chamber 119 and the second stage cyclone chambers 120 may beopenable independently of the cyclone chamber 110.

Wall 140 is preferably configured so that when it is in the closedposition, the lower surface 144 cooperatively engages an upper surfaceof one or more of the sidewalls 108, 111, and 121 a-f. For example, asshown in FIGS. 5 and 6, the lower surface 144 may have one or morechannels or grooves 148 configured to receive the ends of sidewalls 108,111, and 121 a-f when the wall 140 is in the closed position.Optionally, one or more sealing or gasketing elements may be providedbetween groove(s) 148 and the sidewall ends. Alternatively, the lowersurface 144 may be relatively planar, and configured to abut thesidewalls 108, 111, and 121 a-f, with or without gasketing elements.

As exemplified in FIGS. 4 and 11, a second stage dirt collection chamber129 may be associated with each second stage cyclone chamber 120. Asillustrated, each second stage dirt collection chamber 129 a-f is incommunication with a dirt outlet 128 a-f of its respective cyclonechamber 120 a-f to collect the dirt and debris as it exits that secondstage cyclone chamber. Dirt collection chambers 129 a-f may be of anysuitable configuration. Referring to FIGS. 4 and 13, in the illustratedexample, each dirt collection chamber 129 is bounded an upper sidewallextension 141, intermediate wall 140, upper end wall 150, and one ormore interior divider walls 145.

Alternately, two or more second stage cyclone chambers 120 may beassociated with a single second stage dirt collection chamber.Accordingly, for example, a single second stage dirt collection chambermay be provided. Collectively, the second stage dirt collectionchamber(s) may be referred to generally as a second stage dirtcollection region. Accordingly, while in the illustrated example eachsecond stage cyclone chamber 120 a-f has its own associated second stagedirt collection chamber 129 a-f, this need not be the case. For example,fewer or no interior divider walls 145 may be provided, resulting in twoor more second stage dirt outlets being in communication with a sharedsecond stage dirt collection chamber.

As shown in FIGS. 9 and 10, in use air enters each second stage cyclonechamber 120 a-f via an air inlet 122 a-f and exits each chamber 120 a-fvia an air outlet 124 a-f, while separated dirt and debris exits eachcyclone chamber 120 a-f via a dirt outlet 128 a-f, where it collects inthe second stage dirt collection region.

To help facilitate emptying the dirt collection chambers 129 a-f, endwall 150 may be openable. Preferably, end wall 150 is moveable between aclosed position (FIG. 13 and FIG. 5) and an open position (FIG. 4). Whenthe end wall 150 is in the open position, the second stage dirtcollection chambers 129 a-f can be emptied concurrently.

Notably, in the illustrated configuration, when the end wall 150 is in aclosed position and the intermediate wall 140 is in the open position,as shown in FIG. 5, the first stage cyclone chamber 110, the first stagedirt collection chamber 119, and the second stage cyclone chambers 120a-f may be emptied concurrently, while the second stage dirt collectionchambers 129 a-f remain closed.

It will be appreciated that the second stage dirt collection region maybe opened regardless of the position of the upper end 104 (i.e., whetherintermediate wall 140 is open or closed).

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the dirt collection chambers disclosedherein and that, in those embodiments, the dirt collection chambers maybe of various constructions and that in those embodiments any dirtcollection chamber known in the art may be used.

Cyclone Assembly with Openable Ends

The following is a description of a cyclone assembly that may be used byitself in any surface cleaning apparatus or in any combination orsub-combination with any other feature or features disclosed hereinincluding the sizing of a second stage cyclone compared to a first stagecyclone, and the connection of the second stage cyclone chamber airoutlets with an upstream chamber of a pre-motor filter.

FIGS. 23-27 exemplify another embodiment of a cyclone assembly, referredto generally as 100′. Cyclone assembly 100′ may be used as an airtreatment member to remove particulate matter (e.g. dirt, dust) from anair flow. Preferably, the cyclone assembly is removable from the surfacecleaning apparatus. Providing a detachable cyclone assembly 100′ mayallow a user to carry the cyclone assembly 100′ to a garbage can foremptying, without needing to carry or move the rest of the surfacecleaning apparatus 10. Preferably, the cyclone assembly is removable asa closed module, which may help prevent dirt and debris from spillingout of the cyclone assembly 100′ during transport for emptying.

As exemplified in FIG. 23, the cyclone assembly 100′ has a first end102′, a second end 104′, and an outer sidewall 108′. Preferably, anassembly handle (not shown) may be provided to facilitate carrying ofthe cyclone assembly when it is detached from the surface cleaningapparatus 10.

Referring to FIGS. 23-27, cyclone assembly 100′ includes a firstcyclonic cleaning stage and a second cyclonic cleaning stage locateddownstream of the first cyclonic cleaning stage. The first cycloniccleaning stage includes a first stage cyclone chamber 110′ that extendsalong a cyclone axis 115′ and includes a sidewall 111′, which may begenerally cylindrical, extending between a first end wall 150′ and asecond end wall 113′. In the illustrated embodiment, the first stagecyclone chamber 110′ is arranged in a generally horizontal cycloneorientation. Alternatively, the first stage cyclone chamber may beprovided in another orientation, for example as a vertical or inclinedcyclone and may be of any cyclone configuration. Alternatively, or inaddition, the first cyclonic cleaning stage may comprise a plurality ofcyclone chambers instead of a single cyclone.

In the illustrated embodiment, the first stage cyclone chamber 110′includes a first stage cyclone air inlet 112′ and a first stage cycloneair outlet 114′. First stage cyclone chamber 110′ also includes at leastone dirt outlet 118′, through which dirt and debris that is separatedfrom the air flow can exit the cyclone chamber 110′. While it ispreferred that most or all of the dirt exit the first stage cyclonechamber via the dirt outlet 118′, some dirt may settle on the sidewall111′ or the end walls 113′, 150′ of the cyclone chamber 110′ (dependingon the orientation of the cyclone chamber) and/or may be entrained inthe air exiting the first stage cyclone chamber via the air outlet 114′.

In the illustrated example, the first stage cyclone dirt outlet 118′ isin the form of a slot bounded by the cyclone side wall 111′ and thesecond cyclone end wall 113′, and is located toward the second end ofthe cyclone chamber 110′. Alternatively, the dirt outlet may be of anyother suitable configuration, including, for example as an annular gapbetween the sidewall and an end wall of the cyclone chamber or a plateor other suitable member extending towards or into the second end of thecyclone chamber 110′.

Preferably, the first stage cyclone air inlet 112′ is located toward theend of the cyclone chamber 110′ spaced from the end with the dirt outlet(the second end in the illustrated example) and may be positionedadjacent the corresponding cyclone chamber end wall 150′. Preferably,the air inlet 112′ is positioned so that air flowing through the inletand into the first stage cyclone chamber is travelling generallytangentially relative to, and preferably adjacent, the sidewall 111′ ofthe cyclone chamber 110′.

The cross-sectional shape of the air inlet 112′ may be any suitableshape. In the illustrated example of FIG. 23, the air inlet has across-sectional shape that is generally rectangular (e.g., it hasrounded corners and can be referred to as a rounded rectangle) having aheight H_(I) ₁ in the longitudinal direction (i.e. parallel to cycloneaxis 115′) and a width W_(I) ₁ (see FIG. 25) in a transverse directionto cyclone axis 115′. The cross-sectional area of the air inlet 112′ maybe referred to as the cross-sectional area or flow area of the firststage cyclone air inlet 112′. Alternatively, instead of being a roundedrectangle, the cross-sectional shape of the air inlet may be anothershape, including, for example, round, oval, square and rectangular.

Referring to FIG. 23, the first stage cyclone chamber 110′ has a heightH_(C) ₁ in the longitudinal direction (i.e. parallel to cyclone axis115′), being the distance between the second end wall 113′ and first endwall 150′. The height of the first stage cyclone chamber 110′ ispreferably selected such that air entering the cyclone chamber via inlet112′ is expected to rotate approximately 3 to 6 times, 3 to 5 times, 2to 4 times or three-and-a-half times in the first stage cyclone chamberprior to exiting the cyclone chamber via outlet 114′.

In general, it may be assumed that the airflow against the cyclonechamber sidewall as it progresses around the cyclone chamber maintains adegree of cohesion, and that during each revolution within a cyclonechamber, an air stream moves in the longitudinal direction towards anend of the cyclone chamber by a distance approximately equal to theheight of the cyclone chamber air inlet. For example, in a cyclonechamber that has a longitudinal height that is five times greater thanthe longitudinal height of its air inlet, the resulting cyclone may beexpected to rotate about five times as it travels from the end of thecyclone chamber that has the air inlet to the opposite end of thecyclone chamber.

Thus, in order to promote the formation of a cyclone that is expected torotate about three-and-a-half times in the first stage cyclone chamber110′, the height of the first stage cyclone chamber 110′ may be between3 and 4 times the height of the first stage cyclone air inlet 112′.

Air may exit the first stage cyclone chamber 110′ via the first stageair outlet 114′. Preferably, the cyclone air outlet is positioned in oneof the cyclone chamber end walls and, in the example illustrated, ispositioned in the opposite end as the air inlet 112′ and air outlet 114′may be positioned adjacent or at the end wall 113′. As exemplified, theair outlet 114′ may be generally circular in cross-sectional shape.Preferably, the cross-sectional or flow area of the first stage cycloneair outlet 114′ is generally equal to the flow area of the first stagecyclone air inlet 112′. In the illustrated example, the cyclone airoutlet 114′ comprises a vortex finder 116′.

Air exiting the first stage air outlet 114′ may be directed into achamber, header or manifold 117′. From there, the air is directed intothe second cyclonic cleaning stage through one or more air flowpassages. The second cyclonic cleaning stage includes a plurality ofsecond stage cyclone chambers 120′ arranged in parallel. In theillustrated embodiment, seven second stage cyclone chambers are shown,referred to as 120 a′, 120 b′, 120 c′, 120 d′, 120 e′, 120 f′, and 120g′, respectively.

In the illustrated embodiment, each second stage cyclone chamber 120′ isarranged in a generally horizontal cyclone orientation (e.g., the axisof the second stage cyclones are substantially parallel to, or parallelto the axis of the first stage cyclone). It will be appreciated that, inuse, the cyclones may be of various orientations. The second stagecyclone chambers may be of any cyclone configuration.

In the illustrated embodiment, each second stage cyclone chamber extendsalong a respective cyclone axis 125′ (see e.g. FIGS. 23 and 26) andextends between a second end wall 130′ and a first end wall 113′. In theillustrated embodiment, each second stage cyclone chamber is bounded bya sidewall 121 a′, 121 b′, 121 c′, 121 d′, 121 e′, 121 f′, and 121 g′,respectively.

In the illustrated embodiment, each second stage cyclone chamber 120′includes an airflow passage 123′ extending from manifold 117′ to asecond stage cyclone air inlet 122′ and a second stage cyclone airoutlet 124′. Each second stage cyclone chamber 120′ also includes atleast one dirt outlet 128′, through which dirt and debris that isseparated from the air flow can exit the cyclone chamber 120′. While itis preferred that most or all of the dirt entrained in the air exitingthe first cyclonic cleaning stage exits the second stage cyclonechambers via the dirt outlets 128′, some dirt may settle on thesidewalls 121′ or the end walls 130′, 113′ of the cyclone chambers 120′(depending on the orientation of the cyclone chambers) and/or may beentrained in the air exiting the second stage cyclone chambers via theair outlets 124′.

In some embodiments, all or substantially all of the dirt entrained inthe air exiting the first cyclonic cleaning stage may be removed fromthe airflow by the second cyclonic cleaning stage. This may, forexample, obviate the need to provide a pre-motor filter in the surfacecleaning apparatus 10.

In the illustrated embodiment, the air inlets of the second stagecyclone chambers (i.e. air inlets 122 a′-122 g′) are centrallypositioned, in a transverse or radial direction, in the second cycloniccleaning stage. Also, in the illustrated embodiment, the air inlets ofthe second stage cyclone chambers are axially spaced from and face firststage cyclone air outlet 114′. Providing centrally positioned secondstage cyclone air inlets and/or axially spacing the second stage cycloneair inlets from an air outlet of the first cyclonic cleaning stage mayhave one or more advantages. For example, it may provide for a morecompact design of a second cyclonic cleaning stage and/or cycloneassembly. Also, such a design may facilitate airflow through the firstand second cyclonic cleaning stages with reduced backpressure.

In the illustrated example, each second stage cyclone dirt outlet 128′is in the form of a slot bounded by the cyclone side wall 121′ and thecyclone end wall 130′, and is located toward the second end of thecyclone chamber 120′. Alternatively, the dirt outlet may be of any othersuitable configuration, including, for example, as an annular gapbetween the sidewall and an end wall of the cyclone chamber or a plateor other suitable member extending towards or into the open upper end ofthe cyclone chamber 120′.

Preferably, each second stage cyclone air inlet 122′ is located towardthe end of the cyclone chamber 120′ spaced from the end with the dirtoutlet (the second end in the illustrated example) and may be positionedadjacent the corresponding cyclone chamber end wall 113′. Alternatively,the cyclone air inlet 122′ may be provided at another location withinthe second stage cyclone chamber 120′. Preferably, each air inlet 122′is positioned so that air flowing through the inlet and into a secondstage cyclone chamber is travelling generally tangentially relative to,and preferably adjacent, the sidewall 121′ of that cyclone chamber 120′.

The cross-sectional shape of the air inlet 122′ may be any suitableshape. In the illustrated example each air inlet has a cross-sectionalshape that is generally rectangular, having a height H_(I) ₂ in thelongitudinal direction (i.e. parallel to cyclone axis 125′) and a widthin a transverse direction. The total cross-sectional area of the secondstage air inlets (i.e. the sum of the cross-sectional areas of eachinlet 122 a′, 122 b′, 122 c′, 122 d′, 122 e′, 122 f′, and 122 g′) may bereferred to as the total cross-sectional area or total flow area of thesecond cyclonic cleaning stage.

Referring to FIG. 23, each second stage cyclone chamber 120′ has aheight H_(C) ₂ in the longitudinal direction (i.e. parallel to cycloneaxis 125′). The height of each second stage cyclone chamber 120′ ispreferably selected such that air entering the cyclone chambers viainlets 122′ is expected to rotate approximately 3 to 6 times, 3 to 5times, 2 to 4 times or three-and-a-half times in each second stagecyclone chamber prior to exiting the cyclone chamber via outlet 124′.For example, the height H_(C) ₂ of a second stage cyclone chamber 120′may be between 3 and 4 times the height of a second stage cyclone airinlet 122′.

Air may exit each second stage cyclone chambers 120′ via a second stageair outlet 124′ provided for each cyclone chamber 120′. Preferably, thecyclone air outlets 124′ are positioned in one of the end walls of eachcyclone chamber 120′ and, in the example illustrated, are positioned inthe opposite ends as the air inlets 122′. As exemplified, the airoutlets 124′ may be generally circular in cross-sectional shape.Preferably, the cross-sectional or flow area of each second stagecyclone air outlet 124′ is generally equal to the flow area of thesecond stage cyclone air inlet 122′ for its respective cyclone chamber.In the illustrated example, each cyclone air outlet 124′ comprises avortex finder 126′.

Referring to FIGS. 23 and 25, a first stage dirt collection chamber 119′is in communication with dirt outlet 118′ to collect the dirt and debrisas it exits first stage cyclone chamber 110′. Dirt collection chamber119′ may be of any suitable configuration. In the illustrated example,the dirt collection chamber 119′ is bounded by outer sidewall 108′,first stage cyclone side wall 111′, and first and second end walls 150′,113′ of the first cyclonic cleaning stage.

In use, air enters the first stage cyclone chamber 110′ via air inlet112′ and exits the chamber 110′ via air outlet 114′, while separateddirt and debris exits the cyclone chamber 110′ via dirt outlet 118′,where it collects in the first stage dirt collection chamber 119′.

To help facilitate emptying the dirt collection chamber 119′, at leastone of or both of the end walls 150′, 113′ may be openable. In theillustrated example, end wall 150′ is moveable between a closed position(e.g. FIG. 23) and an open position (e.g. FIG. 24). When the end wall150′ is in the open position, the first stage dirt collection chamber119′ and the cyclone chamber 110′ may be emptied concurrently.

End wall 150′ is preferably configured so that when it is in the closedposition, the inner surface 154′ cooperatively engages an end surface ofone or more of the sidewalls 108′ and 111′. For example, the innersurface 154′ may have one or more channels or grooves configured toreceive the ends of sidewalls 108′ and 111′ when the end wall 150′ is inthe closed position. Optionally, one or more sealing or gasketingelements may be provided between such groove(s) and the sidewall ends.Alternatively, the inner surface 154′ may be relatively planar, andconfigured to abut the ends of sidewalls 108′ and 111′, with or withoutgasketing elements.

As exemplified in FIGS. 23 and 23, a second stage dirt collectionchamber 129′ may be associated with each second stage cyclone chamber120′. As illustrated, each second stage dirt collection chamber 129a′-129 g′ is in communication with a dirt outlet 128 a′-128 g′ of itsrespective cyclone chamber 120 a′-120 g′ to collect the dirt and debrisas it exits that second stage cyclone chamber. Dirt collection chambers129 a′-129 g′ may be of any suitable configuration. In the illustratedexample, dirt collection chamber 129 a′ is bounded by an intermediatewall 140′, second end wall 130′ of the second cyclonic cleaning stage,interior divider walls 145 a′ and 145 g′, and annular divider walls 142′and 144′ of the second cyclonic cleaning stage; dirt collection chamber129 b′ is bounded by intermediate wall 140′, second end wall 130′,interior divider walls 145 a′ and 145 b′, and annular divider walls 142′and 144′; dirt collection chamber 129 c′ is bounded by intermediate wall140′, second end wall 130′, interior divider walls 145 b′ and 145 c′,and annular divider walls 142′ and 144′; dirt collection chamber 129 d′is bounded by intermediate wall 140′, second end wall 130′, interiordivider walls 145 c′ and 145 d′, and annular divider walls 142′ and144′; dirt collection chamber 129 e′ is bounded by intermediate wall140′, second end wall 130′, interior divider walls 145 d′ and 145 e′,and annular divider walls 142′ and 144′; dirt collection chamber 129 f′is bounded by intermediate wall 140′, second end wall 130′, interiordivider walls 145 e′ and 145 f, and annular divider walls 142′ and 144′;and dirt collection chamber 129 g′ is bounded by intermediate wall 140′,second end wall 130′, interior divider walls 145 f′ and 145 g′, andannular divider walls 142′ and 144′.

Alternatively, two or more second stage cyclone chambers 120′ may beassociated with a single second stage dirt collection chamber.Accordingly, for example, a single second stage dirt collection chambermay be provided. Collectively, the second stage dirt collectionchamber(s) may be referred to generally as a second stage dirtcollection region. Accordingly, while in the illustrated example eachsecond stage cyclone chamber 120 a′-120 g′ has its own associated secondstage dirt collection chamber 129 a′-129 g′, this need not be the case.For example, fewer or no interior divider walls 145 a′-g′ or annulardivider wall 144′ may not be provided, resulting in two or more (e.g.all) of the second stage dirt outlets being in communication with one ormore shared second stage dirt collection chamber(s).

In use, air enters each second stage cyclone chamber 120 a′-120 g′ viaan air inlet 122a′-122g′ and exits each chamber 120 a′-120 g′ via an airoutlet 124 a′-124 g′, while separated dirt and debris exits each cyclonechamber 120 a′-120 g′ via a dirt outlet 128 a′-128 g′, where it collectsin the second stage dirt collection region.

In the illustrated embodiment, the second stage dirt collection region(i.e. second stage dirt collection chamber 129 a′-129 g′) is centrallypositioned, in a transverse direction, in the second cyclonic cleaningstage. Also, in the illustrated embodiment, the second stage cyclonechambers are positioned around the second stage dirt collection region(i.e. second stage dirt collection chamber 129 a′-129 g′). Providing acentrally positioned dirt collection region, and/or positioning thesecond stage cyclone chambers around the second stage dirt collectionregion may have one or more advantages. For example, it may provide fora more compact design of a second cyclonic cleaning stage and/or cycloneassembly. Also, such a design may facilitate the provision of a singleshared second stage dirt collection chamber. Further, it may simplfyemptying of the second cyclonic stage.

Also, in the illustrated embodiment, the second stage dirt collectionregion (i.e. second stage dirt collection chamber 129 a′-129 g′) isaxially spaced from first stage cyclone air outlet 114′. Also,intermediate wall 140′ of second stage dirt collection region facesfirst stage cyclone air outlet 114′. Such a configuration may have oneor more advantages. For example, it may provide for a more compactdesign of a second cyclonic cleaning stage and/or cyclone assembly.

Referring to FIG. 23, in the illustrated example, second end wall 130′acts as an end wall for each of second stage cyclones 120 a′-120 g′ andsecond stage dirt collection chambers 129 a′-129 g′. Wall 130′ ismoveable between a closed position (e.g. FIG. 23) and an open position(e.g. FIG. 24). When the end wall 130′ is in the open position, thesecond stage cyclone chambers 120 a′-120 g′ and the second stage dirtcollection chambers 129 a′-129 g′ can be emptied concurrently.

Wall 130′ is preferably configured so that when it is in the closedposition, the inner surface 132′ cooperatively engages an end surface ofone or more of the sidewalls 108′, 121 a′, and 121 b′, interior dividerwalls 145 a′-g′, and annular divider walls 142′, 144′. For example, theinner surface 132′ may have one or more channels or grooves configuredto receive the ends of sidewalls 108′, 121 a′, 121 b′ and/or dividerwalls 145 a′-g′, 142′, and 144′ when the wall 130′ is in the closedposition. Optionally, one or more sealing or gasketing elements may beprovided between such groove(s) and the sidewall and/or divider wallends. Alternatively, the inner surface 132′ may be relatively planar,and configured to abut the sidewalls 108′, 121 a′, 121 b′ and/or dividerwalls 145 a′-g′, 142′, and 144′, with or without gasketing elements.

In the illustrated embodiment, the second end of the first cycloniccleaning stage is proximal to the first end of the second cycloniccleaning stage. For example, as exemplified, end wall 113′ may act asboth a second end wall of the first stage cyclone chamber 110′ and as afirst end wall of the second stage cyclone chambers 120′.

Providing a common end wall between the first and second cycloniccleaning stages may have one or more advantages. For example, it mayprovide for a more compact design of a cyclone assembly. Alternatively,or additionally, such a design may be simpler and/or more economical tomanufacture.

It will be appreciated that, in the illustrated example, the first stagedirt collection region may be opened regardless of the position of thesecond end wall of the second cyclonic cleaning stage (i.e., whether endwall 130′ is open or closed). Similarly, in the illustrated example, thesecond stage dirt collection region may be opened regardless of theposition of the first end wall of the first cyclonic cleaning stage(i.e., whether end wall 150′ is open or closed).

Latching Mechanism

The following is a description of a dual opening latching mechanism thatmay be used by itself in any surface cleaning apparatus or in anycombination or sub-combination with any other feature or featuresdisclosed herein including the sizing of a second stage cyclone comparedto a first stage cyclone, the positioning of a dirt collection regionfor second stage cyclones and the connection of the second stage cyclonechamber air outlets with an upstream chamber of a pre-motor filter.

In accordance with this feature, a latching mechanism with amulti-position switch or release mechanism may be provided toselectively retain the intermediate wall 140 and/or the upper end wall150 in its respective closed position. An advantage of this design isthat it may prevent a user from inadvertently opening both theintermediate wall 140 and the upper end wall 150 at the same time.

As exemplified in FIGS. 16-22, a latching mechanism, referred togenerally as 200, is provided between the intermediate wall 140 and theupper end wall 150. Latching mechanism 200 includes an upper latch forselectively retaining upper end wall 150 in its closed position, and alower latch for selectively retaining intermediate end wall 140 in itsclosed position. A release switch 260 is provided for selectivelydisengaging the upper latch or the lower latch.

Release switch 260 is an actuator that is moveable in two differentdirections, (e.g., left and right). When the actuator is moved in afirst direction, a first locking member is moved to an unlocked positionwhile a second locking member is maintained in a locked position. Whenthe actuator is moved in a second direction, which may be an oppositedirection to the first direction, the second locking member is moved toan unlocked position while the first locking member is maintained in alocked position. It will be appreciated that the first and secondlocking members may be separate elements or they may be opposite ends ofa single linkage.

As exemplified in FIGS. 17, 19, and 22, the upper latch includes agenerally U-shaped latching bar 220 that is pivotally coupled to a shaft210. Shaft 210 is parallel to both the intermediate wall 140 and theupper end wall 150. The upper end of the latching bar 220 has adownwardly facing surface 224 that is configured to engage with a lip orflange 225 extending from the upper end wall 150 to cooperatively retainthe end wall 150 in its closed position. When the latching bar 220 is ina locked position (as shown in FIGS. 17 and 22) and upper end wall 150in its closed position, downwardly facing surface 224 overlies flange225, thereby retaining upper end wall 150 in its closed position.Preferably, latching bar 220 is biased towards its locked position, forexample, using a spring or other biasing member(s) (not shown).

The upper end of the latching bar 220 also has an upwardly facing angledor beveled surface 222 that is configured to pivot the latching bar 220away from the locked position when engaged by an angled or beveledsurface 223 of flange 225, thereby allowing the upper latch to beengaged by bringing the end wall 150 to its closed position.

Latching bar 220 also has a flange or projection 226 that extendsgenerally forwardly. As shown in FIG. 17, projection 226 is angled orsloped such that one lateral end of the projection 226 extends furtherforward than the opposite lateral end.

As exemplified in FIGS. 19, 21, and 22, the lower latch includes alatching bar 240 that is also pivotally coupled to shaft 210. The lowerend of latching bar 240 has an upwardly facing surface 244 that isconfigured to engage with a lip or flange 245 extending from the outersidewall 108 to cooperatively retain the intermediate wall 140 in itsclosed position. When the latching bar 240 is in a locked position (asshown in FIGS. 19 and 21) and intermediate wall 140 in its closedposition, upwardly facing surface 244 overlies flange 245, therebyretaining intermediate wall 140 in its closed position. Preferably,latching bar 240 is biased towards its locked position, for example,using a spring or other biasing member(s) (not shown).

The lower end of the latching bar 240 also has a downwardly facingangled or beveled surface 242 that is configured to pivot the latchingbar 240 away from its locked position when engaged by an angled orbeveled surface 243 of flange 245, thereby allowing the lower latch tobe engaged by bringing the intermediate wall 140 to its closed position.

Latching bar 240 also has a flange or projection 246 that extendsgenerally forwardly. As exemplified in FIGS. 17 and 21, projection 246is angled or sloped such that one lateral end of the projection 246extends further forward than the opposite lateral end. Notably,projections 246 and 226 are angled in opposite directions. Thisarrangement facilitates the selective unlatching of either the upper orlower latch using a single multi-position switch or release mechanism.

As exemplified in FIG. 16, the release switch 260 for latching mechanism200 is rotatably or pivotally coupled to a shaft 270. Shaft 270 isgenerally perpendicular to both the intermediate wall 140 and the upperend wall 150. Release switch 260 also includes an outwardly facingprojection or tab 262 to facilitate a user's rotation of switch 260about shaft 270. Release switch 260 also includes an inwardly facingflange or projection 264 that is configured to engage the projections226, 246 of the upper and lower latching bars 220, 240, respectively.

As exemplified in FIGS. 16, 17 and 21, the release switch 260 is shownin a neutral position. In this position, inwardly facing projection 264is not in contact with either projection 226 or projection 246. As therelease switch 260 is pivoted towards the position shown in FIG. 18,projection 264 is brought into abutment with projection 226 of the upperlatching mechanism. Further pivoting of release switch 260 forces theupper latching bar 220 away from its locked position, and therebyunlatching the upper latch (as shown in FIG. 19) and permitting theupper end wall 150 to be moved to an open position.

Alternatively, if the release switch 260 is pivoted towards the positionshown in FIG. 20, projection 264 is brought into abutment withprojection 246 of the lower latching mechanism. Further pivoting ofrelease switch 260 forces the lower latching bar 240 away from itslocked position, and thereby unlatching the lower latch (as shown inFIG. 22) and permitting the intermediate wall 140 to be moved to an openposition.

It will be appreciated that some of the embodiments disclosed herein maynot use any of the features of the latching mechanisms disclosed hereinand that, in those embodiments, mechanisms for retaining theintermediate and upper walls in their closed positions may be of variousconstructions and that in those embodiments any latching or retainingmechanism known in the art may be used.

Air Outlets for Second Stage Cyclones Provided in a Wall of CommonManifold, Which may be a Pre-Motor Filter Chamber

The following is a description of the connection of the second stagecyclone chamber air outlets with an upstream chamber of a pre-motorfilter for the second cyclonic cleaning that may be used by itself inany surface cleaning apparatus or in any combination or sub-combinationwith any other feature or features disclosed herein including the sizingof a second stage cyclone compared to a first stage cyclone, thepositioning of a dirt collection region for second stage cyclones and adual opening latching mechanism.

In accordance with this feature, the air outlets of a plurality ofcyclone chambers that are connected in parallel may be connecteddirectly to an upstream pre-motor filter chamber or manifold.Accordingly, some or all of the air outlets may extend to openingprovided in the manifold. Accordingly, a manifold for the air outlets,which is upstream from the pre-motor filter chamber, is not provided.

Optionally, the upstream pre-motor filter chamber or manifold may bepositioned in facing relationship with the air outlets of a plurality ofcyclone chambers that are connected in parallel. Accordingly, theupstream face of the pre-motor filter may be positioned generallytransverse to the axis of the cyclone air outlets, and the axis of thecyclone air outlets may be generally parallel to the cyclone of whichthey are the air exits. Therefore, for example, the manifold may bepositioned below a second cyclonic cleaning stage and each of the secondstage cyclone air outlets may have an outlet end in a wall of thechamber or manifold. An advantage of this design is that fewer conduitwalls and/or ducting may be required to direct airflow from the secondcyclonic cleaning stage towards the suction unit, which may simplify thedesign and/or construction of the cyclone assembly and/or surfacecleaning apparatus, and/or may reduce backpressure through the surfacecleaning apparatus.

As exemplified in FIGS. 9-11, air exiting the second stage air outlets124 a-f is directed into a chamber or header or manifold 27 bounded bythe lower surface 134 of the lower end wall 130 of cyclone assembly 100and the upper end of the suction unit 20. From there, the air isdirected by the suction motor through the suction unit 20 andsubsequently exhausted out through the clean air outlet 18.

In alternative embodiments, cyclone assembly 100 may include one or moreadditional manifolds downstream of the second stage air outlets 124 a-fso that cyclone assembly 100 has a single assembly air outlet or fewerair outlets than there are second stage cyclone chambers.

As exemplified, the chamber or header or manifold is a pre-motor filterchamber that houses a pre-motor filter. In such a construction, thepre-motor filter chamber may be opened when the cyclone bin assembly isremoved. For example, the cyclone bin assembly may form part of thepre-motor filter chamber (e.g., an upstream wall of the pre-motor filterchamber). An advantage of this design is that the pre-motor filterchamber is opened when the cyclone bin assembly is removed. Accordingly,when a user removes the cyclone bin assembly (e.g. to empty the dirtcollection chamber(s)), the user may also inspect the condition of thepre-motor filter. The pre-motor filter may be any suitable type ofporous filter media, such as a foam filter and/or a felt filter, or anyother suitable pre-motor porous filter media(s) known in the art.Preferably, the pre-motor filter is removable to allow a user to cleanand/or replace the filter when it is dirty.

Typically, a pre-motor filter is provided to prevent particulate matterthat is not removed from the airstream by the cyclonic cleaning stagesfrom being drawn into the suction motor. Otherwise, this unremovedparticulate matter may cause damage to (or otherwise impair) the suctionmotor.

While the use of a pre-motor filter may be effective at protecting thesuction motor, there may be one or more disadvantages. For example, thepre-motor filter may become clogged with particulate matter, requiring auser to clean and/or replace the filter, a task a user may regard asundesirable.

As used herein, the wording “and/or” is intended to represent aninclusive—or. That is, “X and/or Y” is intended to mean X or Y or both,for example. As a further example, “X, Y, and/or Z” is intended to meanX or Y or Z or any combination thereof.

While the above description describes features of example embodiments,it will be appreciated that some features and/or functions of thedescribed embodiments are susceptible to modification without departingfrom the spirit and principles of operation of the describedembodiments. For example, the various characteristics which aredescribed by means of the represented embodiments or examples may beselectively combined with each other. Accordingly, what has beendescribed above is intended to be illustrative of the claimed conceptand non-limiting. It will be understood by persons skilled in the artthat other variants and modifications may be made without departing fromthe scope of the invention as defined in the claims appended hereto. Thescope of the claims should not be limited by the preferred embodimentsand examples, but should be given the broadest interpretation consistentwith the description as a whole.

The invention claimed is:
 1. A cyclone bin assembly for a surfacecleaning apparatus, the cyclone bin assembly having first and secondlongitudinally spaced apart ends, the cyclone bin assembly comprising:(a) a first cyclonic cleaning stage comprising at least one first stagecyclone having a first stage cyclone chamber and a first stage dirtcollection chamber external to the cyclone chamber, the first cycloniccleaning stage having a longitudinal axis and first and secondlongitudinally spaced apart ends wherein the first end is moveablebetween a closed position in which the first stage cyclone chamber andthe first stage dirt collection chamber are closed and an open positionin which the first stage cyclone chamber and the first stage dirtcollection chamber are open; and, (b) a second cyclonic cleaning stagedownstream from the first cyclonic cleaning stage and comprising aplurality of second stage cyclones in parallel and at least one secondstage dirt collection chamber external to the cyclone chambers, whereineach of the plurality of second stage cyclones has a second stagecyclone chamber, the second cyclonic cleaning stage having alongitudinal axis and first and second longitudinally spaced apart ends,wherein each of the second stage cyclone chambers has first and secondlongitudinally spaced apart ends and the at least one second stage dirtcollection chamber has first and second longitudinally spaced apartends, wherein the second cyclonic cleaning stage is axially aligned withand faces the first cyclonic cleaning stage whereby the first end of thesecond cyclonic cleaning stage is proximal to the second end of thefirst cyclonic cleaning stage and the second end of the second cycloniccleaning stage is axially spaced from the first end of the secondcyclonic cleaning stage, and wherein the second end of the secondcyclonic cleaning stage is moveable between a closed position in whichthe second end of each of the second stage cyclone chambers and thesecond end of the at least one second stage dirt collection chamber areeach closed concurrently and an open position in which the second end ofeach of the second stage cyclone chambers and the second end of at leastone second stage dirt collection chamber are each opened concurrently.2. The cyclone bin assembly of claim 1 wherein the at least one secondstage dirt collection chamber is centrally positioned, in a transversedirection, in the second cyclonic cleaning stage.
 3. The cyclone binassembly of claim 2 wherein the second stage cyclone chambers arepositioned around the at least one second stage dirt collection chamber.4. The cyclone bin assembly of claim 3 wherein the at least one secondstage dirt collection chamber comprises a plurality of second stage dirtcollection chambers.
 5. The cyclone bin assembly of claim 3 wherein theat least one second stage dirt collection chamber comprises a singlesecond stage dirt collection chamber.
 6. The cyclone bin assembly ofclaim 1 wherein the at least one second stage dirt collection chamber isaxially spaced from and faces an air outlet of the first stage cyclonechamber.
 7. The cyclone bin assembly of claim 1 wherein the first stagecyclone chamber has an air outlet at the second end of the firstcyclonic cleaning stage, the second stage cyclone chambers have airinlets at the first end of the second cyclonic cleaning stage and thefirst end of the second cyclonic cleaning stage faces the second end ofthe first cyclonic cleaning stage.
 8. The cyclone bin assembly of claim1 wherein the first stage cyclone chamber has an air inlet at the secondend of the first cyclonic cleaning stage, an air outlet at the secondend of the first cyclonic cleaning stage and the dirt outlet is providedat the second end of the first cyclonic cleaning stage and the secondstage cyclone chambers have air inlets at the first end of the secondcyclonic cleaning stage.
 9. The cyclone bin assembly of claim 8 whereinthe second stage cyclone chambers have air outlets at the second end ofthe second cyclonic cleaning stage.
 10. The cyclone bin assembly ofclaim 8 wherein the air inlets of the second stage cyclone chambers arecentrally positioned, in a transverse direction.
 11. The cyclone binassembly of claim 10 wherein the air inlets of the second stage cyclonechambers are axially spaced from and face an air outlet of the firstcyclonic cleaning stage.
 12. The cyclone bin assembly of claim 1 whereinthe first end of the first cyclonic cleaning stage and the second end ofthe second cyclonic cleaning stage are provided at the first and secondlongitudinally spaced apart ends of the cyclone bin assembly.
 13. Thecyclone bin assembly of claim 1 wherein the first stage cyclone chamberhas an air outlet at the second end of the first cyclonic cleaning stageand the first stage cyclone chamber has a dirt outlet provided at thesecond end of the first cyclonic cleaning stage and wherein the secondstage cyclone chambers have air outlets at the second end of the secondcyclonic cleaning stage and the second stage cyclone chambers have dirtoutlets provided at the second end of the second cyclonic cleaningstage.
 14. The cyclone bin assembly of claim 13 wherein the second stagecyclone chambers have air inlets at the first end of the second cycloniccleaning stage.
 15. The cyclone bin assembly of claim 14 wherein the airinlets of the second stage cyclone chambers are centrally positioned, ina transverse direction.
 16. A cyclone bin assembly for a surfacecleaning apparatus, the cyclone bin assembly having first and secondlongitudinally spaced apart ends, the cyclone bin assembly comprising:(a) a first cyclonic cleaning stage comprising at least one first stagecyclone having a first stage cyclone chamber and a first stage dirtcollection chamber external to the cyclone chamber, the first cycloniccleaning stage having a longitudinal axis and first and secondlongitudinally spaced apart ends wherein the first end is moveablebetween a closed position in which the first stage cyclone chamber andthe first stage dirt collection chamber are closed and an open positionin which the first stage cyclone chamber and the first stage dirtcollection chamber are open; and, (b) a second cyclonic cleaning stagedownstream from the first cyclonic cleaning stage and comprising aplurality of second stage cyclones in parallel and at least one secondstage dirt collection chamber external to the cyclone chambers, whereineach of the plurality of second stage cyclones has a second stagecyclone chamber, the second cyclonic cleaning stage having alongitudinal axis and first and second longitudinally spaced apart ends,wherein each of the second stage cyclone chambers has first and secondlongitudinally spaced apart ends and the at least one second stage dirtcollection chamber has first and second longitudinally spaced apartends, wherein the second cyclonic cleaning stage overlies the firstcyclonic cleaning stage, and wherein the second end of the secondcyclonic cleaning stage is moveable between a closed position in whichthe second end of each of the second stage cyclone chambers and thesecond end of the at least one second stage dirt collection chamber areeach closed concurrently and an open position in which the second end ofeach of the second stage cyclone chambers and the second end of the atleast one second stage dirt collection chamber are each openedconcurrently.
 17. The cyclone bin assembly of claim 16 wherein the firststage cyclone chamber has an air outlet at the second end of the firstcyclonic cleaning stage, the second stage cyclone chambers have airinlets at the first end of the second cyclonic cleaning stage and thefirst end of the second cyclonic cleaning stage faces the second end ofthe first cyclonic cleaning stage.
 18. The cyclone bin assembly of claim16 wherein the first stage cyclone chamber has an air inlet at thesecond end of the first cyclonic cleaning stage, an air outlet at thesecond end of the first cyclonic cleaning stage and the dirt outlet isprovided at the second end of the first cyclonic cleaning stage and thesecond stage cyclone chambers have air inlets at the first end of thesecond cyclonic cleaning stage.
 19. A cyclone bin assembly for a surfacecleaning apparatus, the cyclone bin assembly having first and secondlongitudinally spaced apart ends, the cyclone bin assembly comprising:(a) a first cyclonic cleaning stage comprising at least one first stagecyclone having a first stage cyclone chamber and a first stage dirtcollection chamber external to the cyclone chamber, the first cycloniccleaning stage having a longitudinal axis and first and secondlongitudinally spaced apart ends wherein the first end is moveablebetween a closed position in which the first stage cyclone chamber andthe first stage dirt collection chamber are closed and an open positionin which the first stage cyclone chamber and the first stage dirtcollection chamber are open and wherein the first stage cyclone chamberhas an air outlet at the second end of the first cyclonic cleaningstage; and, (b) a second cyclonic cleaning stage downstream from thefirst cyclonic cleaning stage and comprising a plurality of second stagecyclones in parallel and at least one second stage dirt collectionchamber external to the cyclone chambers, wherein each of the pluralityof second stage cyclones has a second stage cyclone chamber, the secondcyclonic cleaning stage having a longitudinal axis and first and secondlongitudinally spaced apart ends, the second stage cyclone chambers haveair inlets at the first end of the second cyclonic cleaning stage andthe first end of the second cyclonic cleaning stage faces the second endof the first cyclonic cleaning stage, wherein each of the second stagecyclone chambers has first and second longitudinally spaced apart endsand the at least one second stage dirt collection chamber has first andsecond longitudinally spaced apart ends, wherein the first end of thesecond cyclonic cleaning stage is proximal to the second end of thefirst cyclonic cleaning stage and the second end of the second cycloniccleaning stage is axially spaced from the first end of the secondcyclonic cleaning stage, and wherein the second end of the secondcyclonic cleaning stage is moveable between a closed position in whichthe second end of each of the second stage cyclone chambers and thesecond end of the at least one second stage dirt collection chamber areeach closed concurrently and an open position in which the second end ofeach of the second stage cyclone chambers and the second end of the atleast one second stage dirt collection chamber are each openedconcurrently.